BAHAMAS, BOLIVIA, BELIZE, CANADA, CHILE, TAIWAN,
COLOMBIA, COSTA RICA, DOMINICAN REPUBLIC,
ECUADOR, EL SALVADOR, GUAM, GUATEMALA, Document

Countries: GUYANA, HAITI, HONDURAS, JAMAICA, KOREA, hd 0800482
SOUTH KOREA, MEXICO, ARUBA, NICARAGUA,
PANAMA, PERU, TRINIDAD AND TOBAGO, UNITED

STATES, URUGUAY, VENEZUELA, Curagao
I Ow Availability: ISIS, Bus ISIS, FleetISIS, NotSIR Revision: 24
Seltem: — Electical Created: 2/19/2014

Knowledge Base Current Last

Language: English Modified: 4/24/2024
Other «, Anthony
Languages: ESraiiol, Author: Tondola
i: 18985
¥v
Copy Link Copy Relative Link Bookmark ‘Add to Favorites Print Provide Feedback Helpful Not Helpful

G > _

Title: Battery Testing, Diagnostics, and Maintenance information

View My Bookmarks

Applies To: All Vehicles

Change Log

Please refer to the change log text box below for recent changes to this article:

19/05/2019 - Updated links to CTS-1100 Warranty Policy & Procedure Manual

1/29/2018 - Fixed hyperlink for Midtronics manual

1/26/2018 - Spanish translation updated.

1/20/2018 - Requested translation for Spanish

0/22/2018 - Added clarification to step 2, updated the Midtronics manual hyperlink
14/2016 - Updated Odyssey selections for testing...

Description

This document covers battery diagnostics, maintenance, and storage requirements. Failure to follow the instructions can result in a false
indication of a failed battery(s)

If the battery is being tested under 55 (Parts over the counter warranty), the AutoMeter BCT-468NAVK Tester should be used.
If the vehicle is equipped with Odyssey Batteries please file a warranty claim through Navistar.

© If equipped with Odyssey Batteries, select SPIRAL when prompted for Battery Chemistry.

© The Midtronics EXP Tester may still be used for battery diagnostics and Warranty Authorization Code (WAC) generation.

Symptoms

Diagnostic Trouble Codes & Dashboard Indicator Lights:

DTC/Light Description

No Faults or Warning Lights

Customer Observations or Concerns:

© No Crank

© Hard to start

© Low voltage on the gauge
Repeated jump starts

Special Tools / Software

‘Tool Description [Toot Number [comments [instructions
AutoMeter Battery and Electrical BCT-468NAVK Instruction
System Analyzer Manual
Diagnostic Steps
[step][action [Decision
Pre-Test Inspection
1. Inspect for loose connections at the battery and connected
components (Starter, Alternator, Ground, etc...)
1 2. Remove any corrosion with battery cleaning spray, or baking Go to Step 2
soda/water paste. Then rinse clean.
Have all connections been found tight, and without corrosion?
[step [Action [Decision
Individual Battery Test
1. Connect the tool to the individual battery as outlined on page 28 of _||"Good Battery" >
the AutoMeter BCT-468NAVK Tester instructions. Battery diagnostics
© If the batteries have threaded studs, screw the negative (-) stud
adapter onto the negative terminal, and the positive (+)
adapter onto the positive terminal. (Stud adapters pg 11 of
AutoMeter Instructions) "Replace Battery"
or "Bad Cell-Replace" >
2 2. Perform the battery test as described on page 28. Go to Step 3
© Test each battery individually for accurate results.
© Keep all generated Warranty Authorization Codes (WAC) during
testing to later be submitted on Warranty Claim (If 01, 03, 39 or
55 warranty applies)
—————————————| charge batterie toa
Charge batteries toa
© Navistar only uses Group 31 batteries for battery type minimum 75% (12.6V)
© If equipped with Odyssey Batteries, select SPIRAL for battery and return to Step 2
chemistry
What were the individual test results for each Battery?
[step][action |Decision
3. [Battery Replacement Yes : Continue to Starter

1. Replace only the batteries that the tester has failed.

2. The technician must ensure that the open circuit voltage of the new
battery is near the voltage of the remaining batteries in the pack, to
avoid arcing and overheating of the terminals as the new battery is
being installed.

¢ Replace bad batteries with the same part number as the remaining
good batteries

diagnostics located in
1KO800407

(For ISB applications go
to : IKO800503 )

Do not mix battery types. AGM, flooded, or hybrid must be matched
with the same.

Do not mix CCA (Cold Cranking Amp) or RC (Reserve Capacity)
ratings.

For sleeper applications, do not use flooded batteries. Use only AGM
or other Navistar approved parts. No : Release the Vehicle

Is- Me/S! ei i 2

Warranty Information

Warranty Claim Coding:

[Group: |Jossso - Batteries / Battery Run Down Protection

710 - Battery, Cranking

Nouns: | 742 - Battery, Auxiliary

Standard Repair Time(s):

Step _| [Description [srt tink [Hours
12 Battery Test |A08-2710A, ISRT Time
3 |[Battery Replacement Model Dependent. ||SaT Time

Special Requirements

Dealers: For each battery filed under warranty (01, 03, 39, 55 Over the counter, and service parts), test result codes generated by the
Autometer tester must be printed out, and attached to the claim, or scanned and added as an attachment. Refer to CTS-1100 and
WPL2800114.

If the battery is being placed due to physical damage ( IE cracked body or cap, swelling/leaking ECT), please provide pictures of the damage
with the warranty claim.

The Midtronics EXP Tester may still be used for battery diagnostics and Warranty Authorization Code (WAC) generation.

Fleets: Refer to fleet battery warranty policy.

Appendix

Maintaining Batteries During Vehicle Storage

© Truck and Bus batteries must be maintained during vehicle storage or battery deterioration, or possible failure can result. Battery life
will be shortened if the batteries are not kept properly charged while in storage.

¢ If batteries fail while the vehicle is in storage, or on the lot will not be considered for reimbursement or warranty.

* The Dealer is responsible for adequate storage and protection of new vehicles, whether they are on Dealer premises or elsewhere.
Correct any conditions creating unnecessary expense and/or preventable customer dissatisfaction. When vehicles are delivered directly
to a TEM / body manufacturer, the Dealer should arrange for proper vehicle storage and maintenance. We recommend sending a copy
of these procedures to the body manufacturer.

The complete Navistar Vehicle Storage policy is explained in the Warranty Policy Manual CTS-1100 and WPL2800091

Battery / Battery Pack Charging Chart

Note: This chart is only to be used as a guideline illustrating approximate charge times for certain battery/battery pack conditions.
When a battery or batteries need to be charged the following procedures need to be followed.

* The Midtronics Smart Charger PSC55OCC is the recommended equipment for charging batteries.

© This type of charger will charge the battery or batteries to ensure proper and safe charging without overcharging.

¢ Ifa smart charger is not available, a regular charger can be used. Follow the table below as a guide on how long it takes to charge each
battery.